FR e500 KN INSTRUCTION MANUAL

FR E500 KN INSTRUCTION MANUAL TRANSISTORIZED INVERTER FR E500 FR E520 0 1KN to 7 5K KN INSTRUCTION MANUAL OUTLINE PARAMETERS SPECIFICATIONS INSTALLATION AND WIRING OPERATION/ CONTROL PROTECTIVE FUNCTI[.]

CONTROL

PROTECTIVE FUNCTIONS Chapter 5

Chapter 4 Chapter 3 Chapter 2 Chapter 1

This instruction manual gives handling information and precautions for use of thisequipment.

Incorrect handling might cause an unexpected fault Before using the inverter,please read this manual carefully to use the equipment to its optimum

Please forward this manual to the end user

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have readthrough this instruction manual and appended documents carefully and can use theequipment correctly

Do not use the inverter until you have a full knowledge of the equipment, safetyinformation and instructions

In this manual, the safety instruction levels are classified into "WARNING" and

Note that even the CAUTION level may lead to a serious consequence according toconditions Please follow the instructions of both levels because they are important

to personnel safety

WARNING

CAUTION

1 Electric Shock Prevention

! If power is off, do not remove the front cover except for wiring or periodicinspection You may access the charged inverter circuits and get an electricshock

! Before starting wiring or inspection, switch power off, wait for more than 10minutes, and check for residual voltage with a meter (refer to chapter 2 for furtherdetails) etc

! Earth the inverter

! Any person who is involved in the wiring or inspection of this equipment should befully competent to do the work

! Always install the inverter before wiring Otherwise, you may get an electric shock

! Do not change the cooling fan while power is on

It is dangerous to change the cooling fan while power is on

! While power is on, do not move the station number and baudrate setting switches.Doing so can cause an electric shock

2 Fire Prevention

CAUTION

! Mount the inverter and brake resistor on an incombustible surface Installing theinverter directly on or near a combustible surface could lead to a fire

! If the inverter has become faulty, switch off the inverter power A continuous flow

of large current could cause a fire

! When a brake resistor is used, use an alarm signal to switch power off.Otherwise, the brake resistor will overheat abnormally due a brake transistor or

! Always make sure that polarity is correct to prevent damage etc.

! While power is on and for some time after power-off, do not touch the inverter orbrake resistor as they are hot and you may get burnt

4 Additional instructions

Also note the following points to prevent an accidental failure, injury, electric shock, etc.(1) Transportation and installation

CAUTION

! When carrying products, use correct lifting gear to prevent injury

! Do not stack the inverter boxes higher than the number recommended

! Ensure that installation position and material can withstand the weight of theinverter Install according to the information in the Instruction Manual

! Do not operate if the inverter is damaged or has parts missing

! Do not hold the inverter by the front cover or operation panel; it may fall off

! Do not stand or rest heavy objects on the inverter

! Check the inverter mounting orientation is correct

! Prevent screws, wire fragments or other conductive bodies or oil or otherflammable substance from entering the inverter

! Do not drop the inverter, or subject it to impact

! Use the inverter under the following environmental conditions:

Ambient

temperature Constant torque : -10°C to +50°C (non-freezing)

Ambient humidity 90%RH or less (non-condensing)

5.9m/s2 or less (conforming to JIS C 0400)

*Temperatures applicable for a short time, e.g in transit

! The electronic overcurrent protection does not guarantee protection of the motorfrom overheating.

! Do not use a magnetic contactor on the inverter input for frequentstarting/stopping of the inverter

! Use a noise filter to reduce the effect of electromagnetic interference Otherwisenearby electronic equipment may be affected

! Take measures to suppress harmonics Otherwise power harmonics from theinverter may heat/damage the power capacitor and generator

! When parameter clear or all clear is performed, each parameter returns to thefactory setting Re-set the required parameters before starting operation

! The inverter can be easily set for high-speed operation Before changing itssetting, fully examine the performances of the motor and machine

! In addition to the inverter's holding function, install a holding device to ensuresafety

! Before running an inverter which had been stored for a long period, alwaysperform inspection and test operation

1 OUTLINE 1

1.1 Pre-Operation Information 1

1.1.1 Precautions for operation 1

1.2 Basic Configuration 3

1.2.1 Basic configuration 3

1.3 Structure 4

1.3.1 Appearance and structure 4

1.3.2 Functions 5

1.3.3 Inverter communication specifications 5

1.3.4 CC-Link Ver 1.10 6

1.3.5 Communication with remote devices 6

1.3.6 Removal and reinstallation of the front cover 7

1.3.7 Removal and reinstallation of the wiring cover 8

1.3.8 Removal and reinstallation of the accessory cover 9

1.3.9 Exploded view 10

2 INSTALLATION AND WIRING 11 2.1 Installation 11

2.1.1 Instructions for installation 11

2.2 Wiring 13

2.2.1 Terminal connection diagram 13

2.2.2 Wiring of the Main Circuit 16

2.2.3 Wiring of the control circuit 20

2.2.4 Wiring of CC-Link communication signals 23

2.2.5 Connection to the PU connector 26

2.2.6 Connection of stand-alone option units 29

2.2.7 Design information 31

2.3 Other Wiring 32

2.3.1 Power supply harmonics 32

2.3.2 Japanese harmonic suppression guideline 33

2.3.3 Inverter-generated noise and reduction techniques 36

2.3.7 Instructions for compliance with the European standards 46

3 OPERATON/CONTROL 48 3.1 Inverter Setting 48

3.1.1 Pre-operation checks 48

3.1.2 Inverter station number setting 49

3.1.3 Setting of the transmission baudrate setting switch 50

3.1.4 Power on 50

3.1.5 Confirmation of the operation mode 51

3.2 Function Overview 52

3.2.1 Function Block Diagram 52

3.2.2 Function overview 53

3.3 Communication Specifications 55

3.3.1 I/O signal list 55

3.3.2 Assignment of remote registers 57

3.3.3 Instruction Codes 58

3.4 Programming Examples 59

3.4.1 Reply code definitions 59

3.4.2 Program example for reading the inverter status 60

3.4.3 Operation mode setting program example 61

3.4.4 Program example for setting the operation commands 62

3.4.5 Program example for monitoring the output frequency 62

3.4.6 Parameter reading program example 63

3.4.7 Parameter writing program example 64

3.4.8 Running frequency setting program example 65

3.4.9 Alarm definition reading program example 66

3.4.10 Inverter resetting program example 67

3.4.11 Instructions 68

4 PARAMETERS 69 4.1 Parameter List 69

4.1.1 Parameter list 69

4.1.2 List of parameters classified by purpose of use 75

4.2.1 Torque boost (Pr 0, Pr 46) 77

4.2.2 Output frequency range (Pr 1, Pr 2, Pr 18) 78

4.2.3 Base frequency, base frequency voltage (Pr 3, Pr 19, Pr 47) 79

4.2.4 Multi-speed operation (Pr 4, Pr 5, Pr 6, Pr 24 to Pr 27, Pr 232 to Pr 239) 80

4.2.5 Acceleration time (Pr 7, Pr 8, Pr 20, Pr 21, Pr 44, Pr 45) 81

4.2.6 Electronic overcurrent protection (Pr 9, Pr 48) 83

4.2.7 DC injection brake (Pr 10 to Pr 12) 84

4.2.8 Starting frequency (Pr 13) 85

4.2.9 Load pattern selection (Pr 14) 85

4.2.10 Stall prevention (Pr 22, Pr 23, Pr 66) 87

4.2.11 Acceleration/deceleration pattern (Pr 29) 89

4.2.12 Regenerative brake duty (Pr 30, Pr 70) 90

4.2.13 Frequency jump (Pr 31 to Pr 36) 91

4.2.14 Speed display (Pr 37) 92

4.2.15 Up-to-frequency sensitivity (Pr 41) 93

4.2.16 Output frequency detection (Pr 42, Pr 43) 93

4.2.17 Monitor display (Pr 52) 94

4.2.18 Automatic restart after instantaneous power failure (Pr 57, Pr 58) 96

4.2.19 Shortest acceleration/deceleration mode (Pr 60 to Pr.63) 97

4.2.20 Retry function (Pr 65, Pr 67 to Pr 69) 99

4.2.21 Applied motor (Pr 71) 101

4.2.22 PWM carrier frequency (Pr 72, Pr 240) 102

4.2.23 Reset selection/disconnected PU detection/PU stop selection (Pr 75) 103

4.2.24 Parameter write disable selection (Pr 77) 105

4.2.25 Reverse rotation prevention selection (Pr 78) 106

4.2.26 Operation mode selection (Pr 79) 107

4.2.27 General-purpose magnetic flux vector control selection (Pr 80) 108

4.2.28 Offline auto tuning function (Pr 82 to Pr 84, Pr 90, Pr 96) 109

4.2.29 Computer link operation (Pr 117 to Pr 124, Pr 342) 115

4.2.30 Output current detection function (Pr 150, Pr 151) 127

4.2.31 Zero current detection (Pr 152, Pr 153) 128

4.2.32 Stall prevention (Pr 156) 129

4.2.36 Output terminal (remote input) function selection (Pr 190 to Pr 192) 134

4.2.37 Cooling fan operation selection (Pr 244) 135

4.2.38 Slip compensation (Pr 245 to Pr 247) 136

4.2.39 Ground fault detection at start (Pr 249) 137

4.2.40 Stop selection (Pr 250) 138

4.2.41 Output phase failure protection selection (Pr 251) 139

4.2.42 Communication error "E.OPT" operation selection (Pr 500 to Pr 502) 140

5 PROTECTIVE FUNCTIONS 142 5.1 Errors (Alarms) 142

5.1.1 Operation at Alarm Occurrence 142

5.1.2 Error (alarm) definitions 143

5.1.3 To know the operating status at the occurrence of alarm 149

5.1.4 Correspondence between digital and actual characters 150

5.1.5 Resetting the inverter 150

5.1.6 How to Check for Error using the LEDs 151

5.2 Troubleshooting 154

5.2.1 Motor remains stopped 154

5.2.2 Motor rotates in opposite direction 154

5.2.3 Speed greatly differs from the setting 154

5.2.4 Acceleration/deceleration is not smooth 155

5.2.5 Motor current is large 155

5.2.6 Speed does not increase 155

5.2.7 Speed varies during operation 155

5.2.8 Operation mode unswitched to CC-Link operation mode 156

5.2.9 Inverter unstarted in CC-Link operation mode 156

5.2.10 Parameter write cannot be performed 156

5.3 Precautions for Maintenance and Inspection 157

5.3.1 Precautions for maintenance and inspection 157

5.3.2 Check items 157

5.3.3 Periodic inspection 158

5.3.4 Insulation resistance test using megger 158

5.3.5 Pressure test 158

5.3.6 Daily and Periodic Inspection 159

5.3.8 Measurement of main circuit voltages, currents and powers 164

6 SPECIFICATIONS 166 6.1 Standard Specifications 166

6.1.1 Model specifications 166

6.1.2 Common specifications 167

6.1.3 Outline dimension drawings 169

APPENDIX 173 APPENDIX 1 Data Code List 173

! InverterMitsubishi transistorized inverterFR-E500 series

! Pr

Parameter number

! CC-LinkControl & Communication Link

1 OUTLINE

1.1 Pre-Operation Information

1.1.1 Precautions for operation

This manual is written for the FR-E500 series Control & Communication Link (hereafterreferred to as "CC-Link") type transistorized inverters

Incorrect handling may cause the inverter to operate incorrectly, causing its life to bereduced considerably, or at the worst, the inverter to be damaged Handle the inverterproperly in accordance with the information in each section as well as the precautionsand instructions of this manual to use it correctly

For handling information on the parameter unit (FR-PU04), stand-alone options, etc.,refer to the corresponding manuals

(1) Unpacking and product check

Unpack the inverter and check the capacity plate on the front cover and the rating plate

on the inverter side face to ensure that the product agrees with your order and theinverter is intact

1) Inverter type

Inverter type Serial number

Capacity plate

Rating plate Capacity plate

Rating plate

FR-E520-0.1KN/

Inverter type Input rating

Output rating Serial number

MITSUBISHI MODEL

INVERTER

FR-E520-0.1KN

INPUT : OUTPUT : SERIAL : XXXXX XXXXX

PASSED

Products supporting CC-Link Ver.1.10 has a logo

Inverter Indicates capacity

(2) Preparation of instruments and parts required for operation

Instruments and parts to be prepared depend on how the inverter is operated Prepare

equipment and parts as necessary (Refer to page 48.)

(3) Installation

To operate the inverter with high performance for a long time, install the inverter in a

proper place, in the correct direction, with proper clearances (Refer to page 11.)

(4) Wiring

Connect the power supply, motor and operation signals (control signals) to the terminal

block Note that incorrect connection may damage the inverter and peripheral devices

(See page 13.)

(5) Grounding

To prevent an electric shock, always use the motor and inverter after grounding them

The ground cable provided for reduction of induction noise from the power line of the

inverter is recommended to be run by returning it up to the ground terminal of the

inverter (Refer to page 39)

1

as well as the precautions and instructions of this manual (For connections of theperipheral devices, refer to the corresponding manuals.)

AJ61 BT11 CPU

(MC)

(NFB) or (ELB)

Ground

Ground

DC reactor (FR-BEL)

AC reactor (FR-BAL)

Earth leakage circuit breaker

or no-fuse breaker Power supply

Magnetic contactor

Inverter

Manuals for CC-Link master station

Master station

Terminal resistor

CC-Link dedicated cable

Up to 42 inverters can be connected.

Terminal resistor

AJ61BT11/A1SJ61BT11 Control &

Communication Link System Master/

Local module User's Manual IB-66721

AJ61QBT11/A1SJ61QBT11 Control &

Communication Link System Master/

Local module User's Manual IB-66722

QJ61BT11 Control &

Communication Link System Master/

Local module User's Manual IB-080016

Japanese Harmonic Suppression Guideline

The "harmonic suppression guideline for household appliance and general-purposeproducts" issued by Ministry of Economy, Trade and Industry (formerly Ministry ofInternational Trade and Industry) in September, 1994 applies to 3-phase 200V class

(2) Without accessory cover and front cover

POWER lamp (yellow)

Operating status indicator LEDs Control logic changing connector Control circuit terminal block

PU connector*

ALARM lamp (red)

Transmission baud rate setting switch CC-Link terminal block

Main circuit terminal block Wiring cover

Station number setting switches

* Use the PU connector for the FR-PU04 (option) and RS-485 communication

1

rate setting switch

Switch used to set the transmission speed

For details, refer to page 50

POWER lamp (yellow) Lit to indicate that power is input (present)

ALARM lamp (red) Lit to indicate that a protective function is activated

Operating status

indicator LEDs

L.RUN : Lit to indicate normal receipt of refresh data Extinguished

when data is interrupted for some time

SD : Extinguished to indicate that send data is "0"

RD : Lit to indicate detection of carrier in receive data

L.ERR : Lit to indicate the communication error of the station itself

Flickers to indicate that the switch or other setting waschanged while power is on

1.3.3 Inverter communication specifications

Form Terminal block connection system (disconnectable from

inverter front)Number of units connected Maximum 42 units (1 station/unit occupied), other models

may also be used

Terminal block connected 6-terminal block (M2×6 screws)

Cable size 0.75 to 2mm2

Station type Remote device station

Number of stations occupied One inverter occupies one station

Connection cable CC-Link dedicated cable, CC-Link Version 1.10 compatible

CC-Link dedicated cable

1.3.4 CC-Link Ver 1.10

The conventional CC-Link products, whose inter-station cable lengths have equally

been changed to 20cm (7.87 inch) or more to improve the inter-station cable length

restriction, are defined as CC-Link Ver 1.10 In comparison, the conventional products

are defined as CC-Link Ver 1.00

Refer to the CC-Link Master Module Manual for the maximum overall cable lengths and

inter-station cable lengths of CC-Link Ver 1.00 and Ver 1.10

(1) CC-Link Ver 1.10 compatibility conditions

1) All modules that comprise a CC-Link system should be compatible with CC-Link Ver

1.10

2) All data link cables should be CC-Link Ver 1.10 compatible, CC-Link dedicated

cables (CC-Link Ver 1.10 compatible cables have a logo or Ver 1.10

indication.)

Note: In a system that uses the CC-Link Ver 1.00 and Ver 1.10 modules and

cables together, the maximum overall cable length and inter-station cable

length are as specified for CC-Link Ver 1.00

(2) How to confirm the CC-Link Ver 1.10 compatible products

Only the FR-E520-KN units manufactured in and after September 2001 are CC-Link

SERIAL number

2) Product having a logo on its body

Refer to page 1 for the SERIAL and logo positions on the body

1.3.5 Communication with remote devices

(1) When the CPU has automatic refresh function (example: QnA series

CPU)

Through communication with the corresponding devices using sequence ladder

logic, data is automatically transferred to/from the refresh buffer of the master

station at the execution of the END instruction to perform communication with the

remote devices

(2) When the CPU does not have automatic refresh function (example:

AnA series CPU)

Data is transferred to/from the refresh buffer of the master station directly by

sequence ladder logic to perform communication with the remote devices

1

1.3.6 Removal and reinstallation of the front cover

"

" Removal

(For the FR-E520-0.1KN to 3.7KN)

The front cover is secured by catches in positions A and B as shown below.Push either A or B in the direction of arrows, and using the other end as asupport, pull the front cover toward you to remove

A

B

(For the FR-E520-5.5KN, 7.5KN)

The front cover is fixed with catches in positions A, B and C

Push A and B in the directions of arrows at the same time and remove thecover using C as supporting points

C

B C

A

"

" Reinstallation

Note: 1 Make sure that the front cover has been reinstalled securely.

2 The same serial number is printed on the capacity plate of the front cover

and the rating plate of the inverter Before reinstalling the front cover, check

the serial numbers to ensure that the cover removed is reinstalled to the

inverter from where it was removed

1.3.7 Removal and reinstallation of the wiring cover

"

" Removal

The wiring cover is fixed by catches in positions 1) and 2)

Push either 1) or 2) in the direction of arrows and pull the wiring cover

1.3.8 Removal and reinstallation of the accessory cover

"

" Removal

Hold down the portion A indicated by the arrow and lift the right hand sideusing the portion B indicated by the arrow as a support, and pull out theaccessory cover to the right

Mounting position

Accessory cover Catch

2)

C H A P T E R 2

INSTALLATIONAND

WIRING

This chapter gives information on the basic "installation and

wiring" for use of this product.

Always read the instructions in this chapter before using the

INSTALLATION AND WIRING

2 INSTALLATION AND WIRING

2.1 Installation

2.1.1 Instructions for installation

When mounting any of the FR-E520-0.1KN to 0.75KN, remove the accessory cover,front cover and wiring cover

1) Handle the unit carefully

The inverter uses plastic parts Handle it gently to protect it from damage

Also, hold the unit with even strength and do not apply too much strength to the frontcover alone

2) Install the inverter in a place where it is not affected by vibration easily (5.9m/s2maximum.)

Note the vibration of a cart, press, etc

3) Note on ambient temperature

The inverter life is under great influence of ambient temperature In the place ofinstallation, the ambient temperature must be within the permissible range -10°C to+50°C Check that the ambient temperature is within the permissible range in thepositions shown in Fig 3)

4) Install the inverter on a non-combustible surface

The inverter will be very hot (maximum about 150°C) Install it on a non-combustiblesurface (e.g metal) Also leave sufficient clearances around the inverter

5) Avoid high temperatures and high humidity

Avoid direct sunlight and places of high temperature and high humidity

6) Avoid places where the inverter is exposed to oil mist, flammable gases, fluff, dust,dirt etc

Install the inverter in a clean place or inside a "totally enclosed" panel which doesnot accept any suspended matter

7) Note the cooling method when the inverter is installed in an enclosure.

When two or more inverters are installed or a ventilation fan is mounted in an

enclosure, the inverters and ventilation fan must be installed in proper positions with

extreme care taken to keep the ambient temperatures of the inverters with the

permissible values If they are installed in improper positions, the ambient

temperatures of the inverters will rise and ventilation effect will be reduced

8) Install the inverter securely in the vertical direction with screws or bolts

3) Note on ambient

temperatures

Measurement position Measurement position

or more Leave sufficient clearances above

and under the inverter to ensure adequate ventilation.

Cooling fan built in the inverter

1cm or more*

1cm or more*

(Correct example) (Incorrect example)

Position of Ventilation Fan

Inverter

Built-in cooling fan (Correct example) Inverter Inverter

When more than one inverter is contained

(Incorrect example)

Inverter Inverter

8) Vertical mounting

2

INSTALLATION AND WIRING

P24 P24

A B C

U V W P1 ( + )P PR ( − )N (Note 1) (Note 2)

(Note 2)

DA DB DG FG

DA DB DG SLD

SW1 SW2 SW3

SINK SOURCE

POWER LED ALARM LED L.RUN LED

SD LED

RD LED L.ERR LED

Control input signals

(no voltage input allowed)

Jumper Remove this jumper when using the optional power-factor improving DC reactor.

Brake resistor connection

Motor IM Ground

Alarm output

Main circuit terminal Control circuit input terminal Control circuit output terminal Ground

PU connector (RS-485)

Sink-source changing (Indicator)

(L 1 ) (L 2 ) (L 3 ) MC

SLD SLD

Note: 1 0.1K and 0.2K do not contain a transistor

2 Terminals SD and P24 are common terminals Do not earth them to theground

(1) Description of the main circuit terminals

P (+), N ( − ) Brake unit connection Connect the optional brake unit or high power factor converter.

P (+), P1 Power factor improving

DC reactor connection

Disconnect the jumper from terminals P-P1 (+-P1) and connect the optional power factor improving DC reactor.

Ground For grounding the inverter chassis Must be earthed.

(2) Description of the control circuit terminals

Setting of Pr 183

"MRS terminal (RY9) function selection"

changes the terminal function.

RES Reset

Used to reset the protective circuit activated Turn on the RES signal for more than 0.1 second, then turn it off The signal can always be reset with the factory setting.

Setting Pr 75 enables reset only at an inverter alarm occurrence.

Common terminal for contact inputs for use in the sink input mode.

In the sink input mode, connection with this terminal switches the signal on and disconnection switches it off.

(note) Alarm output

Contact output indicating that the output has been stopped by the inverter protective function activated 230VAC 0.3A, 30VDC 0.3A Alarm: discontinuity across B-C (continuity across A-C), normal: continuity across B-C (discontinuity across A-C).

Output terminal (remote input) function choices (Pr 190 to Pr 192) change the terminal functions.

Note : Wire the cables for application of voltages to the contact outputs so that they

may be separated from the PLC power at the no-fuse breaker etc If they are

connected to the same power supply as is used by the PLC, the inverter cannot

2

(3) CC-Link communication signals

Connected with the master station and other local stations to make CC-Link communication.

(4) RS-485 communication

PU connector

Communication can be made by the PU connector in accordance with RS-485.

! Compliant standard: EIA Standard RS-485

! Transmission form: Multidrop link system

! Communication speed: Maximum 19200bps

! Overall distance: 500m

2.2.2 Wiring of the Main Circuit

(1) Wiring instructions

1) It is recommended to use insulation-sleeved solderless terminals for power supply

and motor wiring

2) Power must not be applied to the output terminals (U, V, W) of the inverter

Otherwise the inverter will be damaged

3) After wiring, wire off-cuts must not be left in the inverter

Wire off-cuts can cause an alarm, failure or malfunction Always keep the inverter

clean

When drilling mounting holes in a control box or the like, be careful so that chips and

others do not enter the inverter

4) Use thick cables to make the voltage drop 2% or less

If the wiring distance is long between the inverter and motor, a main circuit cable

voltage drop will cause the motor torque to decrease, especially at the output of a

low frequency (A selection example for the wiring length of 20m is shown on page

18.)

5) For long distance wiring, the overcurrent protection may be activated improperly or

the devices connected to the output side may misoperate or become faulty under

the influence of a charging current due to the stray capacitance of the wiring

Therefore, the maximum overall wiring length should be as indicated in the following

table If the wiring length exceeds the value, it is recommended to set "1" in Pr 156

to make the fast-response current limit function invalid (When two or more motors

are connected to the inverter, the total wiring length should be within the indicated

value.)

Inverter Capacity 0.1K 0.2K 0.4K 0.75K 1.5K or

more

Non-low acoustic noise mode 200m 200m 300m 500m 500m

Low acoustic noise mode 30m 100m 200m 300m 500m

Overall wiring length (1.5K or more)

500m maximum 300m

2

6) Connect only the recommended optional brake resistor between the terminalsP-PR (+-PR) Keep terminals P-PR (+-PR) of 0.1K or 0.2K open.

These terminals must not be shorted

0.1K and 0.2K do not accept the brake resistor Keep terminals P-PR (+-PR) open.Also, never short these terminals

7) Electromagnetic wave interference

The input/output (main circuit) of the inverter includes harmonic components, whichmay interfere with the communication devices (such as AM radios) used near theinverter In this case, install the FR-BIF optional radio noise filter (for use in the inputside only) or FR-BSF01 or FR-BLF line noise filter to minimize interference

8) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIFoption) in the output side of the inverter

This will cause the inverter to trip or the capacitor and surge suppressor to bedamaged If any of the above devices are installed, immediately remove them.(When using the FR-BIF radio noise filter with a single-phase power supply, connect

it to the input side of the inverter after isolating the T phase securely.)

9) When rewiring after operation, make sure that the POWER lamp has gone off, andwhen more than 10 minutes has elapsed after power-off, check with a meter etc.that the voltage is zero After that, start rewiring work For some time after power-off,there is a dangerous voltage in the capacitor

Notes on Grounding

" Leakage currents flow in the inverter To prevent an electric shock, the inverterand motor must be grounded

" Use the dedicated ground terminal to ground the inverter (Do not use the screw

in the case, chassis, etc.)

" The ground cable should be as thick as possible Its gauge should be equal to orlarger than those indicated in the following table The grounding point should be

as near as possible to the inverter to minimize the ground cable length

To meet the Low Voltage Directive, use PVC insulated cables larger thanspecified size in brackets ( )

" Ground the motor on the inverter side using one wire of the 4-core cable

(Unit: mm2)Ground Cable GaugeMotor Capacity

200V class2.2kW or less 2 (2.5)

5.5kW, 7.5kW 5.5 (6)

(2) Terminal block layout

FR-E520-0.1KN, 0.2KN, 0.4KN, 0.75KN

P1 N/- P/+ PR

R/L1 S/L2 T/L3 U V W

TB1 Screw size (M3.5) Screw size (M3.5)

N/-R/L1 S/L2 TB2

Screw size (M4)

TB1 Screw size (M4)

FR-E520-5.5KN, 7.5KN

P1 N/- P/+ PR R/L1 S/L2 T/L3 U V W

Screw size (M5)

TB1 Screw size (M5)

(3) Cables, crimping terminals, etc.

The following table lists the cables and crimping terminals used with the inputs (R (L1),

S (L2), T (L3)) and outputs (U, V, W) of the inverter and the torques for tightening the

ening Torque

Tight-N⋅⋅⋅⋅m R, S, T (L 1 , L 2 , L 3 ) U, V, W

R, S, T (L 1 , L 2 , L 3 ) U, V, W

R, S, T (L 1 , L 2 , L 3 ) U, V, W

R, S, T (L 1 , L 2 , L 3 ) U, V, W

Note: 1 The cables used should be 75°C copper cables

2 Tighten the terminal screws to the specified torques

Undertightening can cause a short or misoperation

2

(4) Connection of the power supply and motor

breaker

The power supply cables must be connected

to R, S, T (L 1 , L 2 , L 3 ) If they are connected

to U, V, W, the inverter will be damaged.

(Phase sequence need not be matched.)

U V W

U V W

Connect the motor to U, V, W In the above connection, turning on the forward rotation switch (signal) rotates the motor in the counterclockwise (arrow) direction when viewed from the load shaft.

(L 1 ) (L 2 ) (L 3 ) (L 1 ) (L 2 ) (L 3 )

Motor Ground

Ground terminal

Note: To ensure safety, connect the power input to the inverter via a magnetic

contactor and earth leakage circuit breaker or no-fuse breaker, and use themagnetic contactor to switch power on-off

2.2.3 Wiring of the control circuit

(1) Wiring instructions

1) Terminals SD are common terminals for I/O signals These common terminals must

not be earthed to the ground

2) Use shielded or twisted cables for connection to the control circuit terminals and run

them away from the main and power circuits (including the 200V relay sequence

circuit)

3) The frequency input signals to the control circuit are micro currents When contacts

are required, use two or more parallel micro signal contacts or a twin contact to

prevent a contact fault

4) It is recommended to use the cables of 0.3mm2 to 0.75mm2 gauge for connection to

the control circuit terminals

5) When bar terminals and solid wires are used for wiring, their diameters should be

0.9mm maximum If they are larger, the screw threads may be damaged during

tightening

(2) Terminal block layout

In the control circuit of the inverter, the terminals are arranged as shown below:

Terminal screw size: M2.5

Terminal layout of control circuit P24 P24 SD SD MRS RES NC NC A B C

*

*

*: Keep NC unconnected.

2

(3) Wiring method

1) For wiring the control circuit, use cables after stripping their sheaths

Refer to the gauge printed on the inverter and strip the sheaths to the followingdimensions If the sheath is stripped too much, its cable may be shorted with theadjoining cable If the sheath is stripped too little, the cable may come off

7mm ± 1mm

2) When using bar terminals and solid wires for wiring, their diameters should be

0.9mm maximum If they are larger, the threads may be damaged during tightening.3) Loosen the terminal screw and insert the cable into the terminal

4) Tighten the screw to the specified torque

Undertightening can cause cable disconnection or misoperation Overtightening cancause damage to the screw or unit, leading to short circuit or misoperation

Tightening torque: 0.25 N⋅m to 0.49 N⋅m

* Use a size 0 screwdriver

Note : When routing the stripped cables, twist them so that they do not become loose

In addition, do not solder it

(4) Control logic changing

The input signal logic is factory-set to the sink mode

To change the control logic, the position of the connector beside the control circuitterminal block must be changed

1) Using tweezers etc to remove the connector in the sink logic position and fit it in thesource logic position

Do this position changing before switching power on

Note: 1 Make sure that the front cover has been installed securely.

2 The front cover has a capacity plate and the inverter a rating plate on it

Since these plates have the same serial numbers, always reinstall the

removed cover to the inverter from where it was removed

3 Always install the sink-source logic changing connector in either of the

positions If two connectors are installed in these positions at the same time,

the inverter may be damaged

2) Sink logic type

! In this logic, a signal switches on when a current flows out of the corresponding

signal input terminal

Terminal SD is common to the contact input signals

Terminal SE is common to the open collector output signals

R

R Current

MRS RES SD

AX40

SE RUN

24VDC

R 1

9 R

• Current flow related

to RUN signal Inverter

3) Source logic type

! In this logic, a signal switches on when a current flows into the corresponding signal

input terminal

Terminal P24 is common to the contact input signals

Terminal SE is common to the open collector output signals

R R

Current

RES MRS

24VDC

RUN SE

1 9

R R

• Current flow related

to RUN signal Inverter

2

2.2.4 Wiring of CC-Link communication signals

(1) Terminal block wiring

The terminals for CC-Link communication signals are arranged in the inverter asshown below

Terminal screw size: M2.5

DADBDGSLDSLDFG

(2) Wiring of inverter and PLC

DB DB

DG DG

SLD SLD

FG

PLC CC-Link master module

Power supply

Inverter

Motor

(3) Connection of two or more inverters

Factory Automation can be applied to several inverters which share a link system as

CC-Link remote device stations and are controlled and monitored by PLC user

programs

DA DB DG SLD FG

Inverter DA DB DG SLD FG

DA DB DG SLD FG

Inverter Master module

Terminal

resistor* Terminal resistor*

Shielded twisted cable Shielded twisted cable

*Use the terminal resistors supplied with the PLC

1) Maximum number of units connected to one master station

42 units (when only inverters are connected)

If there are other units, the following conditions must be satisfied

since the number of stations occupied changes with the unit:

{(1 × a) + (2 × b) + (3 × c) + (4 × d)} ≤ 64

a: Number of units occupying 1 station

b: Number of units occupying 2 stations

c: Number of units occupying 3 stations

d: Number of units occupying 4 stations

{(16 × A) + (54 × B) + (88 × C)} ≤ 2304

A: Number of remote I/O station ≤ 64

B: Number of remote device stations ≤ 42

C: Number of local, standby master

and intelligent device stations ≤ 26

(4) Wiring method

1) 1) Use twisted cables (three wire type) after stripping the cable sheaths and twisting

the wires If the sheath is stripped too long, the cable may contact with the adjacent

cable, causing a short circuit If the sheath is stripped too short, the cable may be

disconnected Use the recommended cables For the specifications and availability

of the CC-Link dedicated cable, refer to the CC-Link catalog

Recommended tightening torque: 0.22 N⋅m to 0.25 N⋅m

Use a small flat-blade screwdriver (tip thickness: 0.6mm/full length: 3.5mm)

2

(5) Recommendation of bar terminals

For wiring of the CC-Link communication signals, two CC-Link dedicated cables must

be twisted together and connected to one terminal block

When using bar terminals, the following terminals and tool are recommended

1) Recommended bar terminal, crimping tool

! Company: Phoenix Contact Co., Ltd

! Bar terminal type: AI-TWIN2×0.5-8WH

! Crimping tool type: CRIMPFOX UD6, ZA3

2) Connection of terminal resistor

Connect a terminal resistor between terminals DA-DB of the inverter located at theend

Work the resistor attached to the master unit of the PLC for use as the terminalresistor

Cut. Cut the tube.

Tube

Note: When there is no resistor attached to the

master unit, use a commercially available

110Ω, 1/2W resistor

3) Connection of shield wire of the CC-Link dedicated cable

Twist the shield wire of the CC-Link dedicated cable and connect it to terminal SLD

Shield wire

Note: The two SLD terminals are connected in the inverter

2.2.5 Connection to the PU connector

(1) When connecting the parameter unit using a cable

Use the option FR-CB2# or the following connector and commercially available cable:

<Connection cable>

! Connector : RJ45 connector

Example 5-554720-3, Tyco Electronics Corporation,

! Cable : Cable conforming to EIA568 (e.g 10BASE-T cable)

Example: SGLPEV 0.5mm×4P (Twisted pair cable, 4 pairs),MITSUBISHI CABLE INDUSTRIES, LTD

<Maximum wiring length>

! Parameter unit (FR-PU04): 20m

(2) For RS-485 communication

By removing the accessory cover and using the PU connector, communication

operation can be performed from a personal computer etc

<PU connector pin-outs>

Viewed from the inverter (receptacle side) front

8) to 1)

1) SG 2) P5S 3) RDA 4) SDB

5) SDA 6) RDB 7) SG 8) P5S

Note: 1 Do not connect the PU connector to a computer's LAN board, FAX modem

socket or telephone modular connector Otherwise, the product may be

damaged due to electrical specification differences

2 Pins 2 and 8 (P5S) provide power to the control panel or parameter unit Do

not use these pins for RS-485 communication

3 Refer to page 115 for the communication parameters

<System configuration examples>

1) When a computer having a RS-485 interface is used with several inverters

PU connector (Note 1)

Station 2 Inverter

Station n Inverter

PU connector (Note 1)

PU connector (Note 1)

2

Use the connectors and cables which are available on the market.

Note: 1 Connector: RJ45 connector

Example: 5-554720-3, Tyco Electronics Corporation

2 Cable : Cable conforming to EIA568 (such as 10BASE-T cable)

Example: SGLPEV 0.5mm × 4P (Twisted pair cable, 4 pairs),Mitsubishi Cable Industries, Ltd

(Do not use pins 2) and 8) (P5S).)

2) When a computer having a RS-232C interface is used with inverters

Termination resistor

Distribution terminal

*Commercially available converter is required (Note 3)

10BASE-T cable (Note 2)

PU connector (Note1)

Station 1 Inverter

PU connector (Note1)

Station 2 Inverter

PU connector (Note1)

Station n Inverter

Use the connectors, cables and converter which are available on themarket

Note: 1 Connector: RJ45 connector

Example: 5-554720-3, Tyco Electronics Corporation

2 Cable : Cable conforming to EIA568 (such as 10BASE-T cable)

Example: SGLPEV 0.5mm × 4P (Twisted pair cable, 4 pairs),Mitsubishi Cable Industries, Ltd

(Do not use pins 2) and 8) (P5S).)

3 *Commercially available converter examples

Model: FA-T-RS40Converter

Nagoya Sales Office, Mitsubishi Electric Engineering Co., Ltd